Apparatus and methods for determining stacker capacity

ABSTRACT

A media stacking system suitable for processing flexible substrate sheets includes an elevating stacker support and a controller configured to control the elevating stacker support according to a weight of a cut sheet stack supported by the elevating stacker support in loading positions.

FIELD OF DISCLOSURE

The disclosure relates to media or substrate sheet processing. In particular, the disclosure relates to substrate stacker trays in media processing systems such as printing systems.

BACKGROUND

Related art stacking systems are configured to validate a position of a stacker tray at cycle up, or an initial position. The tray or pallet is raised until a top sensor is reached, and then lowered slightly in preparation for receiving media from a media pathway. When the weight of paper cut sheets stacked on the tray exceeds the capability of a motor of the system to raise tray, a “fault” occurs and a user may be informed. A current method for addressing the fault is to lower the tray to an unloading position, and remove the stack of cut sheets.

SUMMARY

Systems are desired that provide capability to run larger cut-sheet sizes. Larger cut sheets cause a weight of a stack to be greater at a height that is lower than a maximum capacity stack height for a smaller cut sheet size. Because the determining maximum capacity is performed by determining stack height in related art systems, stacks of larger-sized cut sheets may be produced that are difficult to process and impede workflow.

Apparatus and methods are provided that automatically lowers a stacker tray when a stacking process is cycled down, and when the weight of the stack of cut sheets carried by the stacker tray reaches a maximum allowable weight. Apparatus and methods enable a user to set a maximum allowable stack weight at which an elevator-connected stacker tray is caused to lower for unload at the next cycle down.

An embodiment of systems may include a media stacking system suitable for processing flexible substrate sheets, including an elevating stacker support; and a controller, the controller being configured to control the elevating stacker support according to a weight of a cut sheet stack supported by the elevating stacker support in loading positions.

In an embodiment, systems may include non-volatile memory connected to the controller for storing a default fault value, wherein the default fault value corresponds to a weight that exceeds a capacity of an elevator systems connected to the controller and the stacker support. Systems may include a stacker support including a first set of a ribs and a second set of ribs; and a housing, the stacker support being configured move within the housing between a first position and a second position, wherein the first position is a substrate loading position and the second position is a substrate unloading position.

In an embodiment, methods may include a sheet stacking method for cut sheet flexible media processing, including causing a controller to set total stacker tray weight of a stacker tray to a value corresponding to an initial number of cut sheets loaded on the tray; causing the stacker tray to a be positioned at a loading position; causing the stacker tray to receive a cut sheet for forming a cut sheet stack on the stacker tray; determining an adjusted total stacker weight of the stacker tray having the cut sheet; and determining whether the total stacker tray weight matches a predetermined fault weight stored in memory.

In an embodiment, methods may include wherein if the total stacker tray weight matches the predetermined fault weight, lowering the stacker tray to an unloading position. In methods, the initial value may be equal to zero. In an embodiment, methods may include causing the stacker to move to a loading position after the setting the total stacker tray weight to the initial value. In an embodiment, methods may include, wherein if the total stacker tray weight does not math the predetermined fault weight, repeating the steps of receiving a cut sheet for forming a cut sheet stack on the tray, determining an adjusted total weight of the stacker tray, and determining whether the total stacker tray weight matches a predetermined fault weight stored in memory.

Methods may include the memory being non-volatile memory. Methods may include the stacker tray being connected to an elevator system controlled by the controller.

In an embodiment of apparatus, a non-transitory computer-readable medium storing instructions for controlling a stacker tray of media processing system may include causing a controller to set total stacker tray weight of a stacker tray to a value corresponding to an initial number of cut sheets loaded on the tray; causing the stacker tray to a be positioned at a loading position causing the stacker tray to receive a cut sheet for forming a cut sheet stack on the stacker tray; determining an adjusted total stacker weight of the stacker tray having the cut sheet; and determining whether the total stacker tray weight matches a predetermined fault weight stored in memory.

In an embodiment, apparatus may include the computer-readable medium wherein if the total stacker tray weight matches the predetermined fault weight, lowering the stacker tray to an unloading position. In an embodiment, the initial value may be equal to zero. In an embodiment, the instructions may include causing the stacker to move to a loading position after the setting the total stacker tray weight to the initial value. In an embodiment, if the total stacker tray weight does not match the predetermined fault weight, instructions may include repeating the steps of receiving a cut sheet for forming a cut sheet stack on the tray, determining an adjusted total weight of the stacker tray, and determining whether the total stacker tray weight matches a predetermined fault weight stored in memory.

Exemplary embodiments are described herein. It is envisioned, however, that any system that incorporates features of apparatus and methods described herein are encompassed by the scope and spirit of the exemplary embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a diagrammatical front perspective view of a substrate processing system in with an exemplary embodiment;

FIG. 2 shows a diagrammatical front perspective view of a substrate processing system in accordance with an exemplary embodiment;

FIG. 3 shows a diagrammatical front perspective view of a substrate processing system in accordance with an exemplary embodiment;

FIG. 4 shows a substrate stacking and unloading process in accordance with an exemplary embodiment.

DETAILED DESCRIPTION

Exemplary embodiments are intended to cover all alternatives, modifications, and equivalents as may be included within the spirit and scope of the systems and methods as described herein.

Media or substrate processing systems, stacking support apparatus, and substrate stacking methods useful for media processing are provided. In particular, apparatus and methods include a stacking support configured to automatically lower to an unloading position when a maximum cut-sheet capacity is reached.

Provided apparatus include a stacker apparatus of a cut-sheet media processing system such as a printer. FIG. 1 shows a cut-sheet media processing system 100 having a media feed 101 that connects to a media pathway 103. The media pathway extends to various portions of the media processing system and includes a pathway that directs media to a stacking apparatus.

The stacker apparatus includes a stacker tray 107 that is connected to an elevator assembly (not shown). The stacker tray 107 is configured to carry a stack 110 of cut-sheets received from the media pathway 103. The elevator may include a motor, and may be configured to lift and the lower the stacker tray 107 between points A and B, along vertical pathway C. For example, at cycle up or a beginning of a stacking process, the stacker 107 may be positioned at point A. As the stack builds up, the stacker 107 may be caused to lower toward point B. For unloading and/or cycle down, the stacker tray 107 is caused to lower to point B. After unloading, the stacker tray 107 may be caused to ascend to point B for a next stacking process.

The elevator assembly may be connected to a controller for controlling the assembly and moving of the stacker tray 107. The controller may be configured to control stacker tray movement based on a weight of the stack. In particular, the controller may be connected to memory, e.g., non-volatile memory, which stores a default fault value that corresponds to a cut sheet stack weight that exceeds the elevator assembly's motor capability.

The controller or a connected processor may be configured to determine a current weight of a cut-sheet stack on the stacker tray 107. The current weight is determined by accumulating weight as each sheet is placed on the stacker pallet or tray 107 during a stacking process. The weight may be determined by counting a number of sheets, and adding a value to the current weight count that is determined based on characteristics of the added sheet, whether supplied or detected, including a known GSM for the sheet material. In particular, the current weight of a cut-sheet stack of paper on the stacker pallet or tray 107 may be determined according to the following expression: Total_Weight_On_Pallet=Total_Weight_On_Pallet+Weight_of_Current_Sheet, where the Weight_Of_Current_Sheet=((BasisWeight[GSM]*CrossProcessLength[mm]*ProcessLength[mm])/1000000). When the determined total weight reaches a predetermined fault value that is at or immediately below a weight at which a fault such as motor failure is known to occur, the stacker tray may be caused to lower to position B for unloading. The total weight value is cleared each time the stacker pallet or tray 107 is unloaded.

FIG. 2 shows a paper cut sheet stack on a stacker tray that is removed from a media processing system for unloading. The cut sheet stack is 26 inches long by 14.33 inches wide. A stack weight of such a stack may exceed 250 pounds.

FIG. 3 shows a substrate stacking and unloading process in accordance with an embodiment. In particular, FIG. 3 shows a process 300 for stacking and unloading flexible media such as paper sheets. A controller connected to a stacker apparatus of a printing system and a memory module may be configured to control that stacker apparatus according methods as shown in FIG. 3.

At S3001, a total weight of a stacker tray is set to a value that corresponds to 0 cut sheets loaded on the stacker tray. This may be done at cycle up, or upon unloading cut sheets from the stacker tray in the unloading position.

At S3003, the stacker may be caused to be positioned at a loading position. At the loading position, cut sheets may be fed to and stacked on the stacker tray. The stacker may be caused to receive cut sheets for forming a cut sheet stack on the tray at S3005. As each cut sheet is received by the stacker tray, the total weight value of the stacker tray may be adjusted by the controller or connected processor to determine at S3007 an adjusted total stacker weight of the stacker tray having the cut sheet added at S3005.

At S3011, the controller or connected processor may determine whether the total stacker tray weight exceeds a capacity of the elevator assembly's motor. In particular, the controller or connected processor may determine whether the total stacker tray weight matches or exceeds a predetermined fault weight stored in memory. The predetermined fault weight may be equal to or immediately below a weight that exceeds the capability of the elevator assembly's motor.

If the predetermined fault value is not matched or exceeds, then the process may continued to S3015 if no more sheet processing is required, or more repeat S3005-S3011 for further sheet processing. If the predetermined fault value is matched or exceeded, then stacker tray may be lowered at S3015 to an unloading position.

Embodiments as disclosed herein may also include computer-readable media for carrying or having computer-executable instructions or data structures stored thereon. Such computer-readable media can be any available media that can be accessed by a general purpose or special purpose computer. By way of example, and not limitation, such computer-readable media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to carry or store desired program code means in the form of computer-executable instructions or data structures. When information is transferred or provided over a network or another communications connection (either hardwired, wireless, or combination thereof) to a computer, the computer properly views the connection as a computer-readable medium. Thus, any such connection is properly termed a computer-readable medium. Combinations of the above should also be included within the scope of the computer-readable media.

Computer-executable instructions include, for example, instructions and data which cause a general purpose computer, special purpose computer, or special purpose processing device to perform a certain function or group of functions. Computer-executable instructions also include program modules that are executed by computers in stand-alone or network environments. Generally, program modules include routines, programs, objects, components, and data structures, and the like that perform particular tasks or implement particular abstract data types. Computer-executable instructions, associated data structures, and program modules represent examples of the program code means for executing steps of the methods disclosed herein. The particular sequence of such executable instructions or associated data structures represents examples of corresponding acts for implementing the functions described therein.

It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also, various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art. 

1. A media stacking system suitable for processing flexible substrate sheets, comprising: an elevating stacker support; and a controller, the controller being configured to control the elevating stacker support according to a weight of a cut sheet stack supported by the elevating stacker support in loading positions by causing a controller to set total stacker tray weight of a stacker tray to a value corresponding to an initial number of cut sheets loaded on the tray; causing the stacker tray to a be positioned at a loading position causing the stacker tray to receive a cut sheet for forming a cut sheet stack on the stacker tray; determining an adjusted total stacker weight of the stacker tray having the cut sheet; and determining whether the total stacker tray weight matches a predetermined fault weight stored in memory.
 2. The media stacking system of claim 1, comprising: non-volatile memory connected to the controller for storing a default fault value, wherein the default fault value corresponds to a weight that exceeds a capacity of an elevator systems connected to the controller and the stacker support.
 3. The media stacking system of claim 1, comprising the stacker support; and a housing, the stacker support being configured move within the housing between a first position and a second position, wherein the first position is a substrate loading position and the second position is a substrate unloading position.
 4. A sheet stacking method for cut sheet flexible media processing, comprising: causing a controller to set total stacker tray weight of a stacker tray to a value corresponding to an initial number of cut sheets loaded on the tray; causing the stacker tray to a be positioned at a loading position causing the stacker tray to receive a cut sheet for forming a cut sheet stack on the stacker tray; determining an adjusted total stacker weight of the stacker tray having the cut sheet; and determining whether the total stacker tray weight matches a predetermined fault weight stored in memory, wherein if the total stacker tray weight matches the predetermined fault weight, lowering the stacker tray to an unloading position.
 5. (canceled)
 6. The method of claim 4, comprising the initial value being equal to zero.
 7. The method of claim 4, comprising causing the stacker to move to a loading position after the setting the total stacker tray weight to the initial value.
 8. The method of claim 4, wherein if the total stacker tray weight does not math the predetermined fault weight, repeating the steps of receiving a cut sheet for forming a cut sheet stack on the tray, determining an adjusted total weight of the stacker tray, and determining whether the total stacker tray weight matches a predetermined fault weight stored in memory.
 9. The method of claim 4, comprising the memory being non-volatile memory.
 10. The method of claim 4, comprising the stacker tray being connected to an elevator system controlled by the controller.
 11. A non-transitory computer-readable medium storing instructions for controlling a stacker tray of media processing system, the instructions comprising: causing a controller to set total stacker tray weight of a stacker tray to a value corresponding to an initial number of cut sheets loaded on the tray; causing the stacker tray to a be positioned at a loading position causing the stacker tray to receive a cut sheet for forming a cut sheet stack on the stacker tray; determining an adjusted total stacker weight of the stacker tray having the cut sheet; and determining whether the total stacker tray weight matches a predetermined fault weight stored in memory, wherein if the total stacker tray weight matches the predetermined fault weight, lowering the stacker tray to an unloading position.
 12. The computer-readable medium of claim 11, comprising wherein if the total stacker tray weight matches the predetermined fault weight, lowering the stacker tray to an unloading position.
 13. The computer-readable medium of claim 11, comprising the initial value being equal to zero.
 14. The computer-readable medium of claim 11, comprising causing the stacker to move to a loading position after the setting the total stacker tray weight to the initial value.
 15. The computer-readable medium of claim 11, comprising wherein if the total stacker tray weight does not match the predetermined fault weight, repeating the steps of receiving a cut sheet for forming a cut sheet stack on the tray, determining an adjusted total weight of the stacker tray, and determining whether the total stacker tray weight matches a predetermined fault weight stored in memory. 